Method and apparatus for seaming and inspecting hosiery



Dec. 30, 1969 v T. H. DE SPAIN 3,486,471

METHOD AND APPARATUSFOR SEAMING AND INSPECTING HOSIERY 5 Sheets-Sheet 1 Filed March 51, 1966 INVENTOR 7/5 0/{45 HA 6 4ml IBY Dec. 30, 1969 T. H. DE SPAIN 3,486,471

METHOD AND APPARATUS FOR SEAMING AND INSPECTING HOSIERY Filed March 31, 1966 v 5 Sheets-Sheet 2 &' .2.

INVENTOR T e/m5 .DESPA/A/ METHOD AND APPARATUS FOR SEAMING AND INSPECTING HOSIERY Filed March 51, 1966 T. H. DE SPAIN Dec. 30, 1969 5 Sheets-Sheet 5 Dec. 30, 1969 1-. H. DE SPAIN 3,486,471

METHOD AND APPARATUS FOR SEAMING AND INSPECTING HOSIERY Filed March 31, 1966 5 Sheets-Sheet 4 76 VACUUM mas/=50 7704/ & 5440 VAL OF 670 CKl/VG TOE SEWEO v STOCK/1V6 TUBA/E0 01V F 0/? M INVENTOR 7H0 HA5 D'JPA/A/ BY I W;W 1, ATTORN3 Dec. 30, 1969 H, or; IN 3,486,471

METHOD AND APPARATUS FOR SEAMING AND INSPECTING HOSIERY Filed March 31, 1966 5 Sheets-Sheet 5 SOURCE CLUTCH II 5L '\I I BRAKE FIG. 8

FIG. 9

. INVENTOR THOMAS H. DE SPAIN am w W ATTORNEY 3,486,471 METHOD AND APPARATUS FOR SEAMING AND INSPECTION HOSIERY Thomas H. DeSpain, Paducah, Ky., assignor to Southern Textile Machinery Company, Incorporated, Paducah, Ky., a corporation of Kentucky Filed Mar. 31, 1966, Ser. No. 539,095 Int. Cl. Df 39/00; A41h 43/00 US. Cl. 112-121.15 12 Claims ABSTRACT OF THE DISCLOSURE Method and apparatus for seaming the open toe of stockings knit on circular knitting machines and inspecting the seamed stockings on an elongated hollow inspection form. A plurality of inspection forms are supported for movement between an inspection and turning station and seaming station. Open-toed stockings are positioned on forms at the inspecting and turning stations, advanced on the forms to the sewing station where the open toe is closed, then returned to the inspecting and turning station where the stockings are inspected then everted through the hollow forms by vacuum. 1

This invention relates an improved method of closing the toe and inspecting circular knit hosiery and to apparatus used in this operation.

Conventionally, stockings such as womens full fashioned hosiery are knit in the form of an elongated circular tube with the toe end of the hosiery open. The stockings are then individually turned inside-out, by a first operator with the aid of a pneumatic turning apparatus including an elongated hollow form over which the stockings are drawn. After the turning operation, the stockings are delivered, in bundles, to a seaming station where a sewing machine operator picks up the stockings, one at a time, and passes them through the sewing machine to trim and close the open toe while the stockings are in the insideout condition. From the toe closing, or seaming operation,

United States Patent 0 the stockings are delivered, in bundles, to an inspection station where they are manually drawn onto an elongated hollow inspection form and subjected to a visual inspection, both with respect to the body of the stocking and to the seam closing the toe. After the inspection operation, the individual stockings are everted pneumatically through the hollow inspection form and delivered to a collection point in the right-side-out condition. An apparatus of the type conventionally used in both the turning and the inspection operations is illustrated in US. Patent No. 2,957,613 assigned to the assignee of this application.

These repeated manual operations not only slow down production and thereby increase cost of the hosiery but also, the repeated handling of the stockings materially increases the number of seconds due to pulled threads, or the like. Accordingly, efforts have recently been made to reduce the number of manual operations and thereby speed the production of hosiery. These efforts have resulted in the development of apparatus in which a combination turning and inspection form is movable from the inspection station to a sewing station to permit the toe of the stocking to be seamed while it remains on the form. While these devices are capable of increasing production over the old conventional methods outlined above, their use have not been entirely satisfactory in that it has been necessary to inspect the hosiery before the seaming operation, with the result that defective seams or other defects resulting from the seaming operation may not be detected. Also, in at least one such apparatus, it has been necessary for the operator to turn and inspect the hosiery on the form and then wait for the form to deliver the hose to the seaming station and return before the next stocking can be placed on the form.

An important feature of the present invention resides in providing a method and apparatus for the production of hosiery wherein the hosiery is turned on a form at a first work station by a first operator, then advanced on the form to a second work station where a second operator closes the toe of the hosiery while it remains on the form. The hosiery is finally returned to the first work station where the seamed hosiery is inspected by the first operator and subsequently everted through a hosiery receiving passage in the form. A plurality of forms are provided, each mounted on a turret for movement therewith successively past the respective work stations, with the forms being positioned on the turret so that a form will be moved to and from each station simultaneously. A duct system, connected to a source of pneumatic pressure differential, is provided to establish a flow of air through the hosiery receiving passage of the respective forms when they are at the first work station to assist in the turning operations and to evert and convey the inspected hosiery from the apparatus.

Further features and advantages of the invention will become apparent from the following description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of an apparatus embodying the present invention;

FIG. 2 is a side elevation view of the apparatus shown in FIG. 1 and including a portion of the pneumatic duct system;

FIG. 3 is an end elevation view of the apparatus as seen from the left of FIG. 2;

FIG. 4 is an end elevation view as seen from the right in FIG. 2', with certain parts broken away to more clearly show other parts;

FIG. 5 is an enlarged fragmentary sectional view of a portion of the pneumatic duct system employed in the apparatus;

FIG. 6 is a fragmentary sectional view taken on line 66 of FIG. 2;

FIG. 7 is a schematic flow diagram illustrating the successive steps in closing the toe and inspecting hosiery on the apparatus illustrated in FIGS. 1 through 6;

FIG. 9 is a wiring diagram illustrating the control circuitry.

Referring now to the drawings in detail, the apparatus according to the present invention is indicated generally by the reference numeral 10, and shall sometime be referred to herein as a hosiery inspection apparatus, it being understood that the utility of the apparatus is not limited to the inspection of hosiery. The hosiery inspection apparatus 10 includes a frame 11 having a base 12 and a generally rectangular box-like upright portion 13 including front and rear structural walls 14, 15, respectively.

A drive shaft 16 extends through openings in walls 14, 15, and is journalled for rotation therein, as by bearings 17, 18, about a generally horizontal axis. Shaft 16 includes a cantilevered section projecting outwardly from Wall 14, and a relatively large disc, or turret 20, is mounted on the distal end of the cantilevered section for rotation therewith about the longitudinal axis of zhaft 16. Turret 20 is provided with four axial bores 21 extending therethrough, with the respective bores 21 being radially equally spaced adjacent the outer periphery of turret 20, and circumferentially equally spaced therearound.

A plurality of elongated hollow hosiery inspection and turning forms 23, 24, 25, and 26 (hereinafter sometimes called forms or inspection forms) have one end rotatably mounted in each of the respective openings 21 in turret 20 and journalled for rotation therein about Patented Dec. 30, 1969.

3 their respective longitudinal axis, extending generally parallel to the axis of shaft 16, by bearings 27, 28, 29 and 30, respectively. The inspection forms are provided with a hosiery receiving passage 31, 32, 33 and 34, respectively, extending longitudinally therethrough from the free ends 35, 36, 37 and 38 thereof.

A jack shaft 40 is mounted on walls 14, 15, as by bearings 41, 42, for rotation about an axis parallel to and spaced from the axis of shaft 16. A large diameter pulley 43 is mounted on jack shaft 40 and rotatably fixed thereto, as by key 44, for rotation therewith. Suitable drive means, such as electric motor 45 is fixed on base 12 and drives a suitable reduction gear mechanism illustrated generally at 46, through V-belt 47, with reduction gear 46 driving pulley 43 through a second V-belt 48. The gear mechanism 46 includes an electrically actuated clutch and brake mechanism to permit intermittent operation of the Geneva drive mechanism, described below, without interrupting the operation of motor 45.

A locking and drive disc 50 of a conventional Geneva drive mechanism is mounted on jack shaft 40 for rotation therewith in axially spaced relation with pulley 43. Disc 50 is formed with a single arcuate notch 51 formed in its outer periphery, and carries a single drive pin 52 in radial alignment and spaced outwardly from notch 51. Disc 50 cooperates with a transfer plate 55 rotatably fixed, as by key 56 on shaft 16. Transfer plate 55 is provided with four circumferentially equally spaced arcuate notches 57 formed in its outer periphery for engaging the outer periphery of disc 50 to retain shaft 16 against rotation. Four radially extending, circumferentially equally spaced slots 58 are positioned between notches 57 to engage pin 52 upon each revolution of disc 50.

Since notch 51 and pin 52 on disc 50 are radially aligned, transfer wheel 55 will be released for rotation through one quarter revolution when pin 52 is in engagement with slot 58. Thus, it is seen that the specific Geneva drive mechanism shown will provide an intermittent rotation of shaft 16 and turret 20 carried thereon as a result of continuous rotation of shaft 40 by drive motor 45. Also, since transfer wheel 55 is provided with four peripheral notches and four radial slots while disc 50 has only a single drive pin 52 and a single peripheral notch 51, turret 20 will be rotated through 90 at an average rate corresponding generally to the rate of rotation of disc 50, then retained stationary until disc 50 completes a full revolution.

The relative rotational positions of turret 20 and transfer plate 55 is such that, when shaft 16 is held against rotation by transfer plate 55, two diametrically opposed inspection forms are horizontally aligned one on each side of the hosiery inspection apparatus, while the remaining two forms are vertically aligned. As most clearly seen in FIG. 1, this arrangement permits turning and inspecting operator (hereinafter called an inspector) to work at a first work station at the right side of the apparatus (hereinafter called an inspection station) while a sewing machine operator simultaneously works at a second work station (hereinafter called a sewing station) at the left side of the apparatus. Rotation of the turret is such that an inspection form positioned at the inspection station, which is the three oclock position as viewed in FIG. 3, will be successively moved to and momentarily retained at the six oclock, the nine oclock, and the twelve oclock position before ultimately being returned to the three oclock positions.

When the respective inspection forms, for example form 23, are positioned at the inspection station, the hosiery receiving passage 31 therein is in fluid communication with a duct system, which, in turn, is connected to a source of pneumatic pressure differential 56 to induce a flow of air through passage 31 from the free end 35 thereof. The duct system comprises a short section of hollow pipe 60 (see FIG. 6) mounted on the forward face of wall 14, as by flange 61 and bolts 62, and projecting outwardly from wall 14 parallel to shaft 16. Pipe 60 is aligned with and has an open end overlaying the open end of inspection form 23 extending through turret 20 at the inspection station. A first rigid tubular conduit 63 extends through walls 14 and 15, and is rigidly mounted thereon, as by flange 64. Tube 63 terminates in a 90 ell section 65 extending into and establishing fluid communication with the interior of pipe section 60.

A two-way valve, illustrated generally by the reference numeral 70, is seen in FIGS. 2 and 5 is mounted on the other end of tube 63 adjacent the outer surface of wall 15. Valve includes a body portion 71 having an inlet 72, a first outlet 73 and a second outlet 74. A first fluid conduit 75, preferably in the form of a transparent plastic tube having sufficient rigidity to avoid collapsing under relative high vacuum, is rigidly attached, as by band 76, to the first valve outlet 73. Conduit 75 is operatively connected to a source of pneumatic pressure differential (not shown) to establish a flow of air through the duct system to convey stockings therethrough to a conventional counting and stacking apparatus, not shown.

A trap chamber in the form of a transparent cylindrical container 77 is mounted on outlet 74 and depends downwardly therefrom as shown in FIG. 2. Container 77 includes an integrally formed top wall 78 having an annular opening therein surrounded by an upwardly extending flange 79 for receiving outlet 74 of valve 70. A suitable clamp 80 extending around flange 79 releasably retains trap chamber 77 on outlet 74.

Trap chamber 77 has a removable bottom wall 81 which is releasably retained in place by a plurality of resilient clamps 82. The interior of trap 77 is connected to a source of pneumatic pressure diflerential, by a fluid conduit 84, to induce a flow of air through the trap chamber from valve outlet 72. Conduit 84 extends through a suitable opening in the top wall of trap chamber 77, and is retained therein by a suitable bushing 85, and by clamps 86, 87.

An elongated hollow valve element is pivotally mounted, as by bushing 91 and shaft 92, on valve body 71, and has an inlet 93 substantially larger than inlet 72 and in fluid communication therewith. Valve element 90 further includes an outlet 94 having a size and shape generally corresponding to the size and shape of valve outlets 73 and 74 and movable therebetween by a doubleacting fluid cylinder 95 having one end pivotally supported by bracket 96 and pin 97, and having the piston thereof pivotally connected, as by pin 98, to the inlet end of valve element 90. Suitable stops 100, 101 are provided on valve body 71 in position to limit movement of valve element 90 between a first position aligning outlet 94 with outlet 73 and a second position aligning outlet 94 with outlet 74 to place valve element 90 in fluid communication alternately with conduit 75 and conduit 84.

Since the inlet 93 of movable valve element 90 is substantially larger than valve inlet 72, fluid communication therebetween will not be interrupted by the pivotal movement of the valve element 90 between the first and second positions so that a flow of air will be maintained through the valve regardless of the position of movable valve element 90. Air leakage in valve 70 is maintained at a minimum by the arcuate flanges 102, 103 on the valve body slidingly engaging the arcuate end surfaces 104, 105 respectively, of movable valve element 90.

Actuation of fluid cylinder 95 to move valve element 90 between the first and second positions is controlled by a normally open, closed manually switch 106 located on the floor at the inspection station in position to be actuated by the operators foot. Switch 106 controls the position of a solenoid actuated two-way valve 112 (see FIG. 8), located within an enclosure 107 mounted on frame 13, to alternately direct fluid to inlet ports 108 or 109 of fluid motor 95. When switch 106 is in its normally open position solenoid actuated valve 112 directs fluid to inlet 108 to thereby place valve 70 in fluid communication with conduit 84. When switch 106 is closed by the operator the solenoid actuated valve directs fluid to inlet 109 to move valve element 90 into communication with conduit 75.

A pair of foot actuated switches 110 and 111 are positioned on the floor one at the inspection station and the other at the sewing station and are connected in parallel in the electrical circuit controlling the clutch and braking mechanism of reduction gear 46. As indicated in FIG. 8, direct current is normally supplied to the brake 113 through the normally closed contacts 114 of relay Re1, while clutch 115 is normally de-energized. Thus, in the normal condition of the control circuit as indicated in the drawings, the drive mechanism is disabled. When the normally open contacts of switch 110, for example, are closed, alternating current is supplied to the coil of relay Rel to open its normally closed contacts 114 to de-energize and thereby release the brake. At the same time, the normally open contacts 117 are closed and the normally open contacts 116 are closed to maintain current to the coil after switch 110 is open. When switch 111 is operated to close its normally open contacts, alternating current will be directed to the coil of relay Re2 to close the normally open contacts 118 and thereby complete the circuit to provide direct current to the clutch 115. At the same time, the normally open contacts 119 are closed to maintain alternating current to the coil so that the clutch remains energized even though switch 111 is now open.

When the drive disc 50 completes one full revolution, thereby indexing the turret through 90, the normally closed contacts of a manually operable switch 120 are momentarily opened by any suitable means, thereby deenergizing relays Rel and R22 and permitting the circuit to return to its normal condition.

In operation of the hosiery inspection apparatus, the Geneva drive mechanism rotates turret120= to position one of the inspection forms at the inspection station (the three oclock position as viewed from the free ends of the forms) and into fluid communication with the source of fluid pressure. differential to establish a'flow of air from the free end of the insepctio-n form through the valve 70 and trap chamber 77. An inspector at the inspection station on the right side of the machine, again as viewed from the free ends of the forms, places the open toe end of a stocking in the vicinity of the open end of the form with one hand and permits the toe end of the stocking to be drawn into the hollow form by the flow of air therethrough while retaining the welt end of the stocking with the other hand. The operator then draws the welt end of the stocking onto the outer surface of the inspection form to evert the stocking in the usual manner. The inspector then actuates switch 110 and, assuming that the sewing machine operator has previously actuated switch 111, the Geneva drive mechanism will drive turret 20 through 90 to move the form having a stocking thereon from the three to the six oclock position, and to move the next successive form into fluid commuhication with the duct system at the three oclock position.

The above steps are repeated uritil an inspection from having a stocking with an open toe thereon is moved to the nine oclock position where the sewing machine operator (seated at the sewing station on the left side of the apparatus) passes the toe of the stocking hrough an overedge sewing machine 112 to trim any excess material from the open toe and to scam the trimmed open toe of the stocking. The sewing machine operator then actuates switch 111 and, when switch 110 is also actu-' ated, the turret will be rotated to move the form having a stocking with a closed toe thereon from the nine oclock position to the twelve oclock position in clear view of the inspector. In this position the seamed stocking may be visually inspected simultaneously with the everting of a stocking on the form positioned in the three oclock position. When necessary, inspection may be completed during movement of the turret through the next ninety degrees to position the seamed stocking in the three oclock position or, on rare occasions, after reaching the three oclock position.

When a seamed stocking reaches the three oclock position with the inspection form in fluid communication with the duct system, the operator actuates switch 106 (assuming the stocking to have passed the visual inspection) and manually moves the welt end of the stocking slightly toward the free end of the form to loosen the stocking on the form and to permit the stocking to be drawn through the open end of the form and everted to the right-side-out condition. Since switch 106 has been actuated, valve will be positioned to direct the stocking through duct to be delivered to the conventional counting and stacking apparatus.

As soon as the welt end of the inspected stocking passes through the hollow inspection form, the operator releases switch 106, thereby permitting the movable element of valve 70 to establish fluid communication between the form and the trap chamber, and another stocking having an open toe is placed on the form. Thus, in the event that the operator inadvertently releases an open-toed stocking during the initial turning operation, such stocking will then be caught in the trap chamber 77 and will not be delivered to the counting and stacking system with the complete and inspected stockings. Also, if a seamed stocking fails to pass the visual inspection, due to defect either in the body of the stocking or in the seam closing the toe, the inspector does not actually switch 106, but rather permits the defective stocking to be everted through the form and caught in trap chamber 77.

Since two operators, namely the turning and inspection operator and the sewing machine operator, are simultaneously working on stockings supported by separate inspection forms on the turret 20 it is necessary that precautions be taken to prevent rotation of the turret 20 before both operators have completed their separate operations. This is accomplished by providing the two switches and 111 connected in series and positioned so that one switch is to be actuated by each operator after completing his respective operation.

While I have disclosed and described a preferred embodiment of my invention, I wish it understood that I do not intend to be restricted solely thereto, but that I do intend to cover all embodiments thereof which would be apparent to one skilled in the art and which come within the spirit and scope of my invention.

I claim:

1. A hosiery inspection apparatus comprising a turret mounted for rotation about a generally horizontal axis, a plurality of elongated hosiery inspection forms mounted on said turret for rotation therewith about said generally horizontal axis, said forms being radially and circumferentially equally spaced on said turret and each having a free hosiery receiving end with an opening therein and each including a hosiery receiving passage extending longitudinally therethrough and communicating with said opening in said free end, duct means having a source of pneumatic pressure diiferential for inducing flow of air therethrough, drive means for rotating said turret about said horizontal axis to move the respective forms successively between an inspecting and everting station and a sewing station, said drive means including means for intermittently rotating said turret an amount corresponding to the angular spacing of said forms to successively position said forms at said inspection and everting station and at said sewing station, and means establishing fluid communication between said duct means and said hosiery receiving passage when said forms are at said inspecting and everting station to induce a flow of air through said hosiery receiving passage from said free end.

2. A hosiery inspection apparatus as defined in claim 1 wherein said duct means includes first and second fluid conduits each having a source of fluid pressure differential, and wherein said means establishing fluid communication between said duct means and said passage incluudes valve means selectively operable to establish fluid communication between said passage and said first and second fluid conduits alternately.

3. A hosiery inspection apparatus as defined in claim 1 further comprising bearing means mounting said inspection forms on said turret for rotation thereon about their respective longitudinal axes.

4. A hosiery inspection apparatus as defined in claim 1 wherein said duct means comprises a fixed tube for establishing fluid communication with said hosiery receiving passage at said one end of said form, first and second fluid conduits each having a source of pneumatic pressure differential for inducing a flow of air therethrough and valve means operatively connecting said fixed tube to said first and second fluid conduits alternately to provide continuous fluid communication between said tube and one of said fluid conduits to induce a flow of air throgh said form from said free end.

5. A hosiery inspecting apparatus as defined in claim 4 wherein said valve means includes an inlet connected to said tube and first and second outlets connected to said first and second fluid contents, a valve element movable between first and second positions for connecting said inlet to said first and second positions for connecting said inlet to said first and said second outlets alternatively, and selectively operable means for moving said valve element between said first and second positions.

6. A hosiery inspecting apparatus as defined in claim 5 wherein said second conduit includes a trap chamber having means to receive and retain stockings moving therein while permitting a flow of air therethrough.

7. A hosiery inspecting apparatus as defined in claim 5 wherein said selectively operable means includes a fluid motor normally retaining said valve element in said second position, said motor being operable to move said valve element to said first position.

8. A hosiery inspection apparatus as defined in claim 1 wherein said drive means includes motor means, and said means intermittently rotating said turret includes a Geneva drive mechanism operably connecting said turret to said motor for rotation thereby, said Geneva drive being operable to intermittently rotate said turret an amount corresponding to the angular spacing of said forms and to retain said turret against rotation for a predetermined minimum time after each intermittent rotation thereof.

9. A hosiery inspecting apparatus as defined in claim 8 wherein said drive means further includes control means operably connecting said motor means and said Geneva drive mechanism, said control means including means automatically disabling Geneva drive means after each intermittent rotation of a turret.

10. The method of seaming the open toe of stockings knit on a circular knitting machine and inspecting the seamed stockings on an inspection form having an opening in one end thereof in communication with a stocking receiving passage-extending longitudinally through the form, said method comprising the steps of inducing a flow of air through said form from said opening in said one end, manually placing the open toe of a stocking adjacent said opening to permit the flow of air to distend the stocking within said passage while retaining the welt end of the stocking, advancing the welt end of the distended stocking onto said form away from said one end to evert and withdraw the stocking from within said passage and to locate the hosiery in an inspection position on the external surface of the form, seaming the open toe of the stocking while the hosiery remains on the form, visually inspecting the stocking and the toe seam while the stocking remains on the form, and everting the stocking through the stocking receiving passage in the form.

11. The method of seaming and inspecting stockings as defined in claim 10 further including the steps of discontinuing the flow of air through said passage after the stocking has been positioned on the form, and re-establishing the flow of air'through the form after the open toe of the stockings has been seamed.

12. The method of seaming and inspecting stockings as defined in claim 11 wherein the stocking is positioned on the form at an inspection station, said method further including the steps of moving the form with the stocking thereon from the inspection station to a sewing station to discontinue the flow of air through the form while the open toe of the stocking is being seamed closed, and returning the form to the inspection station to re-establish the flow of air through the form.

References Cited UNITED STATES PATENTS 2,493,803 1/1950 Butler 22339 2,657,841 11/1053 Landucci et al. 223--40 2,684,187 7/1954 Kienel 22343 2,890,818 6/1959' Harralson 22343 2,979,802 4/1961 Funchion et al. 22343 XR 3,131,839 5/1964 Norman et al. 22343 3,163,470 12/1964 Brewin et al. 22343 XR 3,327,664 6/1967 Bryan et al. 22343 XR 3,351,033 11/1967 Kienel 1122 3,420,196 1/ 1969 Edwards et al. 1122 FOREIGN PATENTS 340,033 12/1930 England.

639,148 4/ 1962 Canada. 1,395,844 3/1965 France.

MERVIN STEIN, Primary Examiner GEORGE H. KRIZMANICH, Assistant Examiner US. Cl. X.R. 22343 

